Helmet construction



June 3, 1947. G. A. LYON i 2,

HELMET CONSTRUCTION Filed Jain. s, 1945 2 Sheets-Sheet 1 Q/KQQ m E15,;

June 3, 1947. G. A. LYON HELMET CONSTRU CTION 1943 2 Sheets-Sheet 2Filed Jan. 8

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Patented June 3, 1947 V UNITED STATES PATENT OFFICE HELMET CONSTRUCTIONGeorge Albert Lyon, Allenhurst, N. J. Application January 8, 1943 SerialNo. 471,664

1 This invention relates to an improved helmet construction, and isdirected more particularly to a helmet construction which is adapted toprotect the wearer against injury and at the same time act as aninsulator against heat and cold;

Another important object of the invention is the'provision of animproved arrangement for interlocking the outer and inner shells and thesweat band or sweat band base together;

Still another object of the invention is to provide a helmetconstruction of the above characterwhich is so constructed and arrangedthat it may be manufactured efiiciently, quickly and cheaply from sheetmetal or other form retaining sheet material.

It is a further object of the invention to provide a helmet constructionin which there is provided an insulating vacuum chamber for protectingthe head of the wearer against the transmission of either excessive heator excessive cold,

this insulation efiect bein augmented by novel surface treatment of thecorrelated shell parts. It is still another object of the invention toprovide a helmet construction in which the respective parts areconfigurated in a novel manner to impart strengththereto, the partsbeing joined or interlocked by co-engagement of said respectiveconfigurations, thereby to further strengthen the joints or interlocksbetweenthe parts. V Still another object of the invention is toconfigurate the parts of the helmet',these parts being joined at saidconfigurations by an interfitting relationship therebetween; saidconfigurations being constructed and arranged to afford respectiveinter-engaging tapered surfaces on the parts to permit the interlockingtogether of Various sized internal parts to accommodate various headsizes with a standard outer part.

In accordance with the general features of the invention there isprovided herein a helmet con- 8 Claims. (Cl. 2-3) struction into whichis incorporated a plurality of shell like, dome members associated withone another in a' novel manner to be securely attached together and toprovide therebetween a vacuum Figure 3 represents a still furtherenlarged fragmentary cross-sectional View of a modified form of myinvention; n

Figure 4 represents a fragmentary cross-sectional view of anotherembodiment of the invention; t

Figure 5 represents a fragmentary cross-sectional view of anothermodification of the invention; s

Figure 6 represents a fragmentarycross-sectional view of furthermodified'form of the invention;

Figure '7 represents a cross-sectional view of i still another modifiedform of the invention;

Figure 8 represents a fragmentary exploded,

cross-sectional View of the form of the invention shown in Figure 7-;and n V Figure 9representsa cross-sectional view similar to Figure 8wherein the inner shell is shown 1 attached'to the brim and sweat-bandmember.

It ist o be understood that the embodiments shown herein are forillustrative purposes only and may he changed ormodified withoutdeparting from the spirit and scope of the claims herein;

As best shown in Figure 2 a helmet embodying the invention includes anouter portion 10' having an upper dome part II and alower brim portionI2. In the form shown in Figure 2 the dome and brim are integral witheach other and are formed from any formable sheet material. In practice,it is preferred that the parts helmet be formed from thin sheet metal.To the end that the outer cover or shell of the helmet llimay bestrengthened against crushing action, this part, as shown in Figure2,consists' of the above mentioned portions" H and-I2 which are integral.The junction of the portions II and I2 comprises an annular distortionor 3 groove i3 which may be pressed or spun therein, while the extremityof the brim it is provided with a bead id. Additionally, the domeportion. ll may be provided with a plurality of annular stepped sectionsit: to further strengthen the body thereof.

The uppermost crown section of the dome H may be provided with anaperture which is centrally located thereon for purposes to be explainedpresently.

As shown in Figure 2, an inner shell is is provided for the helmet, thisshell being of such a size that when assembled with the outer shell If)it is spaced therefrom to provide an insulation chamber il The marginaledge of the shell i6 is spun or pressed at E8 to provide an annularmarginal distortion or groove shaped similarly to the distortion it ofthe outer shell whereby assembly of the two shells may be accomplishedby merely interfitting the distortions l3 and I8 together.

, The, shell It is provided with a centrally disposed aperture at itsdome, the latter being adapted to be aligned with the aperture in theshell Hi When the distortions l3 and i8 are disposed in interfittingrelationship. The margin of the dome it around the aperture therein ispressed outwardly as at 19, the annular marginal edge of the portionlQ'being bent around the edge of the shell is which defines the centralaperture therein as shown at 2b in Figure 2. To the end that theconnection between the portion is of the inner shell and th crownportion of the outer shell it! may be maintained securely in theirattached relationship, a rivet-like button member 2! having an externalhollow head and a shank portion 22 is inserted in the crown aperture,whereupon the lowermost extremity of the shank portion 22, with theshoulder between the head portion 2| and the shank 22, is compactedaround the interlock 23 as indicated at 23.

If it is desired merely to utilize the body of air between the shells inthe chamber obtain the desired insulating qualities for the helmet thenthe distortions l3 and i8 may be interfitted with each other merely bypress fittingthem together. However, under certain circumstances it isfound desirable to evacuate the chamber I? to obtain a higher degree ofinsulation. This may be accomplished by first securing the distortionsl3 and i8 together and then welding this junction to provide a tightseal. Thereafter the helmet maybe disposed in an evacuated chamberwhereupon the interlock 29 may be formed and the rivet like buttoncompacted into the position shown in Figure 2 to finally seal thechamber H in this atmosphere of reduced pressure. It will be understoodthat when the helmet is then removed from the reduced pressure chamberthat the chamber I! will remain evacuated, the final seal thereof beingobtained by the interlock at the crown thereof. Suitable sealingsubstance may be used at the interlocks 29 and 23 to insure themaintenance of the vacuum. j I

Another highly advantageous feature of the crown interlock abovedescribed is that it cooperates with the interlock between thedistortions I3 and I8 to securely maintain the shells iii and I6immovably in their relative positions, and prevents the inner shell fromassuming a cocked position with respect to the outer shell.

In the event that the chamber I1 is subjected to evacuation as abovedescribed, the insulating qualities of the helmet have been found to be4 greatly increased by a particular combination of surface coatings forthe two shells. This surface treatment comprises the coating of theuppermost surface of each of the shells with a pure white, glossy finishto obtain maximum outward radiation of heat rays and a dark finish onthe under side of each of the shells to obtain maximum heat rayabsorption outwardly. Thus it will be seen that in addition to thenon-conducting characteristics of theevacuated chamber i! there isprovided a surface treatment which effectively prevents the penetrationof residual 1 heat rays which might tend to overcome the insu- 'band 2d,having been previously shaped and lating qualities of the evacuatedchamber H.

The helmet construction is completed by the attachment of a novel,adjustable sweat band arrangement which is adapted to engage the wearershead.

The sweat band shown at 24 is constructed preferably from a band ofrolled sheet metal 24 which may, if desired, be faced with any suitablemoisture absorbing covering such as felt or the like. As will be readilyunderstood, while the parts of the helmet, other than thesweat band, maybe made to standard size and adapted to any size head, the sweat banditself must be so constructed and arranged that various pre determinedsizes thereof may be fitted into the standard shell arrangement.

To this end the sweat bands are rolled, shaped and welded to accommodatevarious head sizes and shapes and are installed in the helmet by astructure which cooperates with the helmet and at the same time withvarious sized and shaped bands. vAs shown in Figure 2 the sweat weldedto a given size, is provided around its outer surface with a web orspider 25 which is, in turn, provided with an inner upstanding margin26, the latter being welded to the outer surface of the band, and anouter upstanding margin 21, the

llto' latter being of curvate cross-section to conform to the curvatureof the distortion 18 in the shell l6. 1

The sweat band, thus assembled, may be fitted into the interior of thehelmet with the marginal wall 2'! in snap-fit engagement with the innerwall of the distortion I8 of the shell l6.

inner surface of the distortion !8 presents different radial dimensionsthroughout its depth due to the curvature thereof and the portions 2'?of the web or spider 25, being resilient, will thus'engagedifierentportions of the surface of the distortion It in accordance with the sizeof the band 25. This. accommodation by the distortion E8 of varioussizes of sweat bands is of course accomplished by means of a dispositionof the different sizes of bands at slightly differrent horizontal planesthrough the helmet as shown at Figure 2, however, it has been found thatthese slight variations are not discernible to the wearer and do not, inany way, detract from the comfort or utility of the completedconstruction. I

- In the fragmentary cross-sectiona1 representation of Figure 3 theinterlock between the outer shell H3 and the inner shell l6 and betweenthe inner shell l6 and the sweat band 28 is accomplished in a slightlydifferent manner.

,-T1I6 peripheral extremity of the shell [:is formed simply by spinningor pressingthe' edge thereof sothatit flares outwardly to provide aflangeeg, the edgetof. whichis interfittedwiththe ihternalty disposedagroove :36 01 the shell 10. After'this interfitting relationship hasbeen obtained the interlock maybe .welded to provide an air-tight sealand, ifdesired, the shell .Hlcan be left in the form shown ormaybecompressedito closeup-the externally -disposedgroove-;-3l.

The shell l6 as shown in this embodiment is furtherprovided with aninwardlydisposed distortion :33 i which extends annularly around theshell and maycomprise eithera continuous internalylyydisposed hump or aplurality of dimples.

The sweat band 28 of this construction is formedasto shape andsizeibyrolling and welding as previously described in connection with the sweatbandit Additionally the sweat band 28 is provided with breather holes34andis rolled at its upper edge to provide an'externally disposed hump35iwhich cooperates with the distor tion 33 in the shell l6.

As. explained in connection with the constructiOH'Qf Figure '2 thecooperating distortions 33 and 35. present angularly disposed surfacestoward each. other which co-engage to retain the sweat bandin-thehelmet. In the event that varying sizes of sweat bands are to beinsertedintoa standard helmet construction, assembled in the manner shown in:Figure 3, the band may be press-fitted into the helmet to providecooperationbet ween the distortions; 33and 35, the relativepositions'ofthese distortionsan'd' the degree of overlap orinterlock therebetween,being. determined by the horizontal dimensions ofcthe sweat band. If theband is smaller than that shown at 28, it will be inserted less distanceinto the helmet and the distortion 35 thereof, .whichpossesses a degreeof flexibility, will be engaged at a diiferent point on itssurface bythedistortion 33 It will be understoodithat the construction of Figure 3may be subjected to evacuation as described in connection with Figure 2and that the surfaces of the shells may be treated in a like mannertoobtain maximum insulation fromiheat rays.

It has been found that certain human skull contours are better adaptedto accommodate a sheet metal headband than are others. case of thelatterit is found thatradaptation of the sweat band to the headis benefitedconsiderably by providing slits, suchas shown as 28a in Figure 3,whereby a degreeof expansibility and contractibility isimparted to theband. I

From. the foregoing it will be seenthat there is provided herein ahelmet construction, the strength of which is reatly amplified byannular distortions formed in both the inner and the outer shells, thesedistortions being so constructed and arranged that they conform totheconfiguration of each other and may be interiitted with one another toeach augment the resistance to crushing pressure of the other.

Furthermore these crush resisting configurations have been utilized tocombinewith and cooperate with the'sweat band structures whereby varioussizes of sweat bands may be installed in a standard helmet shellwithoutrequiring any variation in the shell construction.

. Inthe construction. shown in Figure tithe dome I I of the outershellis formed integrally. with the brim..| .2 thejunction between the twoparts constituting merely an integral curvate connecting section 36.Theshell- I6 is spun or pressed sothat In the the peripheral margin:thereof terminatesijin 1a curvatejportion'fl adaptefd tdnconform .tothe con-.- fi-guration of the curvate :portion 36 of. the; shell l6.gThCgjdlllCtiOI-l betweemthe-dome of thewshell I 6 and: the curvateportion .31 thereof-includes an annular peak 38 whichaffordslastrengthening rib for the-shell 6-, this rib abutting; againstand reinforcingmhe shell H). The edge'ext-remityof the curvate portion731. of; the shell 161's stamped out to form a ;,plurality of fingers359 which were adapted to be bent inwardly ,to' underlie-the. edge of tahorizontaliiangexm of the sweat. band-41L.

It I will ,be understood that a sealymay be obtained between the curvateportions 36 and 3] by .welding orthelikep 1: q 2

In the construction shown in, Figure 5 thesweat band 412 is.disclosedwas an integral part of the shell -I 6 and constitutes theperipheral marginal portion-1 thereof. Intermediate the sweatyband 42and the dome of the I shell 16 an outwardlyadisposed annular bulgedportion is provided shownat 43. :Thisportion 4-3 is defined omits upper.side by an inwardly and upwardly tapering wall 44-whichiis adapted toslidablygrcooperate with the inwardly upwardly tapering wall portion :45of a bulge :46 i formed in therouterrshell l0. 1

cations described 1 above, the -coope-rating adistortions 43 and 46serveto reinforce {the helmet againstcrushing forces and the taperedsurfaces 44 and 415 are adapted to assume different -,ultimate relativepositions to each other hdepending upon the size and shape of theiinternal-partsof thehelmet. 4

Asinthe construction shown in Figure 72 the uppermost rivet-like. buttonassembly maybe incorporated in the constructions shown in Fig-- ures 3,.4 and 5 in. orderfurther to secure the shell; parts ,in their properrelative positions. i

. In the constructionshown in-Figure6 thesweat band l! .is likewiseshown. integral withjthe innershell I6. The sweat-bandconstitutes theperipheral margin of the shell. I6 and isrrolled so that it extendsinwardly .to simulate the .sizeand shapezof the wearers head.'Iheportion of the shell l6, between thedomepart andthe sweat bandthereof, is oonfigurated to; provide .an. :in-

wardly and upwardly tapering wall 48 whichcoof the depth con-1 operateswith I one oranother figurations49 in the shell l0,

. As previously explained,; in connection with the other modifications.ofthe inventiom'the coop-.

crating walls 48 i and 4'9. assume. relative-positionsaccording to thesize of lthe inner members and the variation in their relative positionsis not discernible; and in-no way detracts from-the efiiciencyor'comfortof the helmet. ,If desired, the sweat band 41 of theconstructionshown in Figure 6 may also-* be provided with ventilation:or breathing aperturesi50. i i

In the construction of Figure 6, as in those constructions formerlydescribed, the walls 48 and 49 may be welded together to provide anairtight seal whereupon therivet-likebutton in the crown of the helmetmay beattached in an atmosphere of reduced pressure to provideanevacuated chamber I1. Likewise the surfacesvofthe shells may be treated inthe manner formerly described to augment the'insulating qualities of theevacuated chamber;

In the modified construction disclosed inFia-v ures 7, 8 and 9, thesweat band i5l is formed as. an integral part ofthe brim l2andconstitutes the inner peripheral margin thereof. In- :this,

explained in connection :with th-e modifie construction the dome of thehelmet is made up of inner and outer shell members 52 and 53,respectively; the inner member 52 terminating at itsfllower edge inan'upwardly curved portion 54 andthe. outer member 53 having a dimple 55at the crownthereof. i

..In assembling the parts of this construction the inner shell '52 maybe welded to'the upper surface of the brim 12 as at 56 whereupon theperipheral edge of the shell 53 may be seam welded to the upstandingedge of the portion 54 of the shell 52, thereafter the sealed chamber 51thus provided may be evacuated in any suitable manner. I

.It is to be understood that in the above construction the surfaces ofthe shell members 52 and 53 may be surface treated in the mannerdescribed previously to augment the insulating characteristics of theevacuated chamber 51.

4 .From the foregoin it will be seen that there is provided herein animproved helmet construction which insulates the head of the weareragainst the penetration of heat rays by means of an evacuated chamber,the insulating qualities of which are augmented by a novel arrangementof heat radiating and heat absorbing surfaces. There is also provided ahelmet construction wherein the brim and dome portions may be uniformfor various head sizes and shapes and wherein sweat bands adapted to themany sizes and shapes required may be easily and securely assembled withthe uniform, standard helmet construction. V

' It should be noted that, in all the modifications describedhereinabove, the various surfaces of the nested shells going to make upthe crown or dome part of the helmet may beeoated as described above. Ialso contemplate'that the innersurface of the outer shell may, instead,in-accordance with the features of my invention, be provided with ahighly lustrous or mirrored surface such as is commonly used in thermosbottles" so as to enable an action to occur inmy helmet similar -to thethermal action that takes place in a thermos bottle.

It should further be noted that, in all forms of my invention, there isprovided a helmet particularly adapted for tropical use made up ofnested shells,- each of relatively thin material and sointerrelatedthat, when assembled, they provide a helmet including a crown or domepart and a brim and also provide for the accommodation of suitable meansto' serve the purpose of a headband whereby the helmet may be properlyfitted to the head of the wearer.

:In addition to the foregoing it will be seen that there r-i 'providedherein a helmet construction Whichis efficiently configurated to providemaximum protection against crushing forces, the various. helmet partsbein configurated to also support each other against such crushinforces. a

i What I claim is: r

1. As an article of manufacture, a helmet in. cluding a'shell portionconstructed from form retaining sheet material and having standard sizeand shape for varying head sizes and shapes, a

sweat band structure of a size and shape to confor'm tothe size andconfiguration of the head of a user, means affording a tapering surfaceinteriorly of said shell and'means affording a cooperating taperedsurface on said sweat band structure, aid surfaces being adapted to"engage innoverlapping, interlocking relationship to secure'said sweatband to said shell, the degree ofloverlapping varying in accordance withvaria- 8 tions inthe shape and size of said sweat band structure.- 1

2. Ina helmet constructed from form retaining sheet material, aprotective portion including outer and inner shell sections, the outersection including a dome portion and a brim portion extending radiallyoutwardly therefrom, an annu lar, rigidifying distorted section adaptedtOprovide a tapering surface between said dome and brim portions, saidinner shell including a dome portion constructed and arranged tobe'spaced from said outer shell to define an insulating chambertherewith and having a tapering surface formed to cooperate with thetapering surface of the outer shell and to be disposed in surfaceabutment therewith to present a tapering surface interiorly of thehelmet and a sweat band for said helmet, said sweat band having meansaffording'a tapering surface adapted to overlap and interlock with theinteriorly disposed tapering surface of said protective portion toretain sweat bands in varying sizes in operative posi. tion within thehelmet. I I

3.111 a helmet construction, an outer she assembly formed from formretaining sheet-material, a head engaging band formed of a size andshape to conform to the configuration of the head of a user, said bandbeing adapted to be disposed interiorly of said helmet and having itsupper marginal edge shaped to afford an outwardly extending taperingsurface, means on said shell afiording an inwardly extending taper ingsurface, said surface being adapted to overlie one another ininterlocking engagement to named means including a connecting elementextending through said walls at the crownof the dome, said elementproviding a clinched attachment between said walls.

5. In a helmet construction a dome like shell, finger elements formed atthe peripheral edge of said shell, a head engaging band including avertical portion and an outwardly extending flange formed integrallywith the bottomedge of said vertical portion, the outer edge oi'saidflange having a size and shape conforming to that of the dome like shellat the junction thereof with said fingers, said flange being disposedwith its outer edge engaging said shell at theupper termini of saidfinger and said fingers being distorted inwardly to underlie said flangeto maintain the same in fixed relationship to said shell. 5

6'. In a helmet constructedfrom'form retaining sheet material, an outershell portion'ineluding a dome section and a brim section extendingsubstantially radially therefrom, an inner shell portion including adome section and a head engaging section, said head engagingfsectioncomprising the marginal peripheral portion of said innershell,'attachment means on said outer shell portion disposed at thejunctioniof' the dome section and the brim section, thereof andcooperating attachment means on said inner shell section disposed at thejunction of the dome section and the head engaging section thereof, saidattachment means being constructed and arranged to engage one another toretain said helmet in assembled relationship with said dome sectionsdisposed in spaced relationship to one another and said head engagingsection disposed inwardly of the junction between said shell portions.

7. In a head gear construction, a hollow shell like member including acrown portion and a brim portion, said shell being made of a materialhaving a white heat-reflecting surface, a head engaging band in thelower part of said shell member adjacent the junction of the crown andbrim portions and means for attaching said band to said shell member sothat the band is spaced through a major portion of its width for asubstantial distance from the inner surface of the shell member, saidmeans comprising a second shell spaced throughout a major portion of itsarea from the inner surface of said member so as to define an insulatingchamber between said member and second shell.

8. In a head gear construction, a crown portion having a lower partprovided with an oversize dimension, a shell-like part in and spacedthroughout the major portion of its area from the inner surface of saidcrown portion and including means for receiving head engaging means ofdifferent head dimensions and shapes, and head engaging means includinga sweat band construction having a part for retainingly engaging saidfirst mentioned means, said shell-like part defining an insulatingchamber between aid crown portion and the head of the wearer.

GEORGE ALBERT LYON.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 1,405,061 Mouromtzeff et a1. Jan.31, 1922 2,032,203 Dym Feb. 25, 1936 2,136,473 Sloan et a1. Nov. 15,1938 FOREIGN PATENTS Number Country Date 262,965 Great Britain Dec. 23,1926

